Flexible shroud for power cables

ABSTRACT

A flexible shroud is configured to protect a connection between at least one power take-off cable and a power generation system. The shroud may include a sheet defining at least one edge, the sheet being flexible and including weather-resistant material. The shroud may include at least one flange operably coupled to the sheet along at least a portion of one edge of the sheet, and at least one securing element associated with another edge of the sheet. The flange may be configured to be operably coupled to a power generation system. The sheet may be configured to be wrapped at least partially around at least one power take-off cable extending from the power generation system, and the at least one securing element may be configured to keep the sheet at least partially wrapped around the at least one power take-off cable.

This application claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/______, filed Jun. 25, 2008, [Title: SYSTEMS AND METHODS FOR GENERATING ELECTRIC POWER; Attorney Docket No.: 08350.6990] the disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a shroud for power cables, and more particularly, to a flexible shroud for power cables operably coupled to a system for generating electric power.

BACKGROUND

It may be desirable to generate electric power, for example, in situations in which electric power is not available from an electric power utility, for example, in remote locations and/or locations experiencing a power outage. This may be accomplished, for example, using electric power generation systems that are configured to generate electric power via operation of one or more internal combustion engines to drive an electric machine configured to convert mechanical energy supplied by the one or more engines into electric power.

To receive electric power generated by an electric power generation system, power cables may be connected to the power generation system. For this purpose, a power generation system may include one or more bus bars including electrical connectors for facilitating connection of electric power cables to the power generation system. It may be desirable to provide access to such bus bars from an exterior of the power generation system for ease of connection. Such exterior access, however, may render such bus bars susceptible to harm from weather-related elements, such as rain, snow/ice, and/or wind, which may be undesirable for a number of operational reasons. As a result, it may be desirable to provide protection for the bus bars while still facilitating ease of access to the bus bars from the exterior of the power generation system.

Containment systems for portable power modules are disclosed in U.S. Pat. No. 6,601,542 issued to Campion (“the '542 patent”). The '542 patent discloses containment systems for use with portable power modules that are trailerable over public roads and capable of providing at least approximately one megawatt of electrical power. One embodiment disclosed in the '542 patent includes a shipping container housing a gaseous fuel motor drivably connected to an electrical generator. The shipping container includes an electrical outlet supplied with electric power from the electrical generator. The shipping container does not include, however, any protection for the connection between a power cable and the electrical outlet.

The systems and methods described in an exemplary manner in the present disclosure may be directed to mitigating or overcoming one or more of the drawbacks set forth above.

SUMMARY

In one aspect, the present disclosure includes a flexible shroud configured to protect a connection between at least one power take-off cable and a power generation system. The shroud may include a sheet defining at least one edge, the sheet being flexible and including weather-resistant material. The shroud may include at least one flange operably coupled to the sheet along at least a portion of one edge of the sheet, and at least one securing element associated with another edge of the sheet. The flange may be configured to be operably coupled to the power generation system. The sheet may be configured to be wrapped at least partially around at least one power take-off cable extending from the power generation system, and the at least one securing element may be configured to keep the sheet at least partially wrapped around the at least one power take-off cable.

According to another aspect, a system for generating electric power may include an engine configured to output mechanical power and an electric machine configured to convert mechanical power into electric power. The electric machine may be operably coupled to the engine. The system may further include a housing configured to contain at least one of the engine and the electric machine, the housing including at least one wall configured to define an interior and an exterior of the housing. The system may also include a compartment located at least partially in the interior of the housing, the at least one wall defining an opening for providing access to the compartment from the exterior of the housing. The system may further include a plurality of electrical connectors operably coupled within the compartment, the electrical connectors being configured to receive electric power generated by the system and provide a connection for power take-off cables. The system may also include a flexible shroud operably coupled to the compartment, such that when power take-off cables are coupled to the electrical connectors, the shroud protects at least one of the electrical connectors and/or at least one of the power take-off cables.

According to still another aspect, a method for connecting at least one power take-off cable to a system for generating electric power may include opening an access panel to provide access to a compartment at least partially housing a plurality of electrical connectors operably coupled to the system. The method may further include lifting a flexible shroud having one edge coupled the system to gain access to at least one of the electrical connectors, and connecting an end of a power take-off cable to one of the electrical connectors. The method may further include wrapping a free edge of the shroud around the power take-off cable, and securing the free edge to prevent the shroud from unwrapping from around the power take-off cable.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic, partial cutaway plan view of an exemplary embodiment of a system for generating electric power.

FIG. 2 is a schematic, partial cutaway elevation view of the exemplary embodiment shown in FIG. 1.

FIG. 3 is a schematic perspective view of an exemplary embodiment of power load connections.

FIG. 4 is a schematic perspective view of an exemplary embodiment of a shroud.

FIG. 5 is a schematic perspective view of an exemplary embodiment of a shroud.

FIG. 6 is a schematic perspective view of an exemplary embodiment of a shroud.

DETAILED DESCRIPTION

FIGS. 1 and 2 show an exemplary embodiment of a system 10 for generating electric power. System 10 may include an engine 12 configured to supply mechanical power and an electric machine 14 operably coupled to engine 12 and configured to convert mechanical power into electric power. Engine 12 may be any internal combustion engine, including a spark-ignition engine, a compression ignition engine, a homogeneous-charge compression-ignition engine, and/or a gas turbine engine. Engine 12 may be configured to run on any fuel, such as, for example, gasoline, diesel fuel including bio-diesel fuel, natural gas, ethanol, methanol, hydrogen, and/or any combinations thereof. Other types of engines and fuels are contemplated. Electric machine 14 may be any type of electric generator known to those skilled in the art. For example, electric machine 14 may include a three-phase AC synchronous generator.

System 10 may further include power load connections 16 (e.g., including one or more bus bars) configured to facilitate supply of electric power generated by system 10 to any device or system that receives input of a source of electric power, such as, for example, a power grid. According to some embodiments, a number of systems 10 may be coupled to one another and/or used together to supply additional electric power.

As depicted in FIGS. 1 and 2, exemplary system 10 may include one or more control panels 18 configured to control operation of engine 12, electric machine 14, and/or any systems associated with system 10. For example, control panel(s) 18 may include electronic control systems configured to control operation of engine 12 and/or electric machine 14, such that system 10 supplies electric power in a desired and/or controlled manner. According to some embodiments, control panel 18 may include an interface for providing an operator with information or data relating to operation of engine 12 and/or electric machine 14, and further, may include controls configured to facilitate an operator's ability to control operation of engine 12, electric machine 14, and/or any other systems associated with system 10. For example, control panel 18 may facilitate an operator's control of the electric power output of system 10, for example, by controlling the voltage and frequency of the power output.

According to the exemplary embodiment shown in FIGS. 1 and 2, system 10 may include a housing 20 configured to provide protection to various components of system 10. For example, housing 20 may include walls, for example, opposing side walls 22, a front wall 24, and one or more rear doors 26, a floor 28, and a roof 30, defining an exterior and, possibly also, an interior of housing 20. According to some embodiments, system 10 may include one or more devices 32 configured to facilitate transport of system 10 between sites that may desire a supply of electric power. For example, the exemplary embodiment shown in FIG. 1 includes a number of wheels for facilitating towing of system 10 via a vehicle, such as a truck or tractor (e.g., housing 20 may be in the form at least similar to a trailer configured to be towed in a manner similar to trailers of a tractor trailer rig). Other types of devices 32 (e.g., tracks, wheels configured to travel along railroad tracks, pontoons, and/or skids) known to those skilled in the art are contemplated. As explained in more detail herein, some embodiments of housing 20 may define one or more passages between an exterior of housing 20 and an interior of housing 20.

According to some embodiments, system 10 may include a reservoir 34 (e.g., a fuel tank) within the interior of housing 20 for providing a supply of fuel to engine 12. Reservoir 34 may be coupled to engine 12 via one or more fuels lines (not shown). According to some embodiments, reservoir 34 may be located external to housing 20 and/or fuel may be supplied via an external source, such as, for example, a pipe line for supplying a fuel, such as, for example, gasoline, diesel fuel, natural gas, hydrogen, ethanol, methanol, and/or any combinations thereof.

According to some embodiments, system 10 may include a cooling system 36 configured to regulate the temperature of engine 12 and/or electric machine 14. For example, cooling system 36 may include one or more heat exchangers 38, such as, for example, one or more air-to-air-after-coolers (ATAAC) operably coupled to engine 12 and/or one or more radiators 40, such as, for example, a jacket water radiator, operably coupled to engine 12. According to some embodiments, engine 12 may include one or more turbochargers (not shown), and heat exchanger(s) 38 may be operably coupled to the one or more turbochargers to cool air entering the turbocharger(s). System 10 may include one or more fans (not shown), for example, located between engine 12 and heat exchanger 38. Such a fan may be operably coupled to engine 12 via a drive belt (not shown) and/or may be driven via an electric motor (not shown), and may supply a flow of air to and/or through heat exchanger 38 in order to provide cooling air to heat exchanger 38.

Exemplary radiator(s) 40 may be configured to receive and cool a flow of coolant (e.g., a liquid coolant), which may be circulated into and/or through engine 12 via coolant lines (not shown), thereby cooling engine 12. One or more fans 42 may be associated with radiator 40 and may be configured to provide a flow of cooling air to radiator 40. Fan(s) 42 may be driven, for example, via an electric motor (not shown), which may be coupled to fan 42 via, for example, a belt drive (not shown).

According to some embodiments, engine 12 may include an exhaust system 44 (FIGS. 1 and 2) configured to remove heat and/or combustion products from housing 20. For example, exhaust system 44 may include roof-mounted muffler 46 in flow communication with engine 12. Exhaust system 44 may further include one or more extensions 48 downstream of muffler 46 configured to provide a flow path for exhaust gas from engine 12 to the exterior of housing 20 via muffler 46. For example, as shown in FIG. 1, extension(s) 48 may extend above heat exchanger 38 from muffler 46 to one or more opening(s) 50 in roof 30, such that exhaust gas exits via opening(s) 50.

According to some embodiments, power load connections 16 may be provided at a power interface 52, as shown, for example, in FIG. 3. For example, side wall 22 of housing 20 may define an opening 54, and power interface 52 may include a compartment 56 located at least partially in an interior of housing (e.g., operably coupled to an interior side of side wall 22 of housing 20), such that the interior of compartment 56 is accessible via opening 54.

According to some embodiments, an access panel 58 (see FIGS. 4 and 5) may provide selective access to an interior of compartment 56. Compartment 56 and/or housing 20 may define a peripheral recess 60, which may be provided with a gasket 62 configured to provide a weather-resistant (e.g., water-resistant) sealing engagement with a corresponding surface 64 on a rear side of access panel 58 (FIG. 3). According to some embodiments, access panel 58 may be hingedly coupled to housing 20 and/or compartment 58, for example, along an upper edge 66 of opening 54. Access panel 58 may include one or more latches 68 (e.g., locking latches) configured to secure access panel 58 in a closed position with respect to compartment 56, for example, such that an exterior face of access panel 58 is generally flush with respect to side wall 22 of housing 20. Some embodiments may include a rod (not shown) configured to prop open access panel 58 by extending from a free end of access panel 58 to, for example, a lower portion of peripheral recess 60. Such a rod may be used to hold access panel 58 in an open position, for example, when power take-off cables are connected to power interface 52.

Compartment 56 may include one or more electrical connectors 70 (e.g., in the form of one or more bus bars) (FIG. 3) configured to be connected to power take-off cables 72 (FIG. 5) that extend exterior to housing 20 to a system to be supplied with electric power from system 10. In particular, electrical connectors 70 receive electric power from system 10 (e.g., from the interior of housing 20) and serve to transfer at least a portion of the power to power take-off cables 72. Power take-off cables 72, in turn, supply electric power from system 10 to a system being supplied with electric power, such as, for example, a power grid and/or electrically-operated devices/equipment.

As shown, for example, in FIGS. 4 and 5, system 10 may include a shroud 74 configured to protect power load connections 16 from the elements. For example, shroud 74 may provide protection from rain, snow/ice, and/or wind when power take-off cables 72 are connected to electrical connectors 70 to supply electric power for a desired end use. According to some embodiments, opening 54 may define a generally rectangular shape (see FIG. 5), and shroud 74 may be configured to be operably coupled to compartment 56 along two lateral sides and across the top 66 of opening 54. This may serve to protect power load connections 16 from the elements even when access panel 58 is open to gain access to power load connections 16 of system 10.

According to some embodiments, as shown in FIG. 6, shroud 74 may be formed from a sheet of flexible material, such as, for example, a weather-resistant sheet of material, such as a nylon sheet coated on at least one side with synthetic rubber, such as, for example, a synthetic rubber sometimes marketed as “Hypalon.” For example, referring to FIG. 6, exemplary shroud 74 may be formed from a generally rectangular sheet 76 of material defining one or more flanges 78 and one or more ears 80 along one edge 82 of sheet 76. Flanges 78 and/or ears 80 may be used to operably couple shroud 74 to system 10 at opening 54, for example, along upper edge 66 and lateral side edges 84 and 86 of opening 54. According to some embodiments, at least one side of flanges 78 may include sealing material 92 (e.g., gasket material) for providing a sealing engagement with access panel 58 when access panel 58 is closed.

According to some embodiments, opposite edge 88 of sheet 76 may be provided with one or more securing elements 90, such as, for example, hook and loop fasteners and/or one or more drawstrings. Securing element(s) 90 may be used, for example, to secure an open end of shroud 74 around power take-off cables 72 that extend from bus bars 70 to provide protection from the elements. For example, an open end of shroud 74 may be wrapped at least partially around power take-off cables 72, and securing element(s) 90 may be used to secure and maintain shroud 74 around power take-off cables 72 (see FIG. 5).

According to some embodiments, shroud 74 may serve to provide quick access to compartment 56, while still providing some measure of protection from the elements for power load connections 16. According to some embodiments, when power take-off cables 72 are not connected to electrical connectors 70, shroud 74 may be placed within compartment 56 and access panel 58 may be closed. Latches 68 may be operated to secure access panel 58 in a closed position.

INDUSTRIAL APPLICABILITY

Exemplary system 10 may be used to generate electric power, for example, in situations in which electric power is not available from an electric power utility source, for example, in remote locations and/or locations experiencing a power outage. For example, one or more engines 12 of exemplary system 10 may be configured to output mechanical power and one or more electric machines 14 may be configured to convert mechanical power into electric power. One or more controls 18 may be configured to facilitate control of at least one of engine 12 and electric machine 14. According to some embodiments, housing 20 may be configured to contain at least one of engine 12 and electric machine 14.

According to some embodiments, power load connections 16 may be provided at a power interface 52 (FIG. 3). For example, side wall 22 of housing 20 may define an opening 54, and power interface 52 may include a compartment 56 at least partially located in the interior of housing 20, such that the interior of compartment 56 is accessible via opening 54. According to some embodiments, access panel 58 (see FIGS. 4 and 5) may provide selective access to an interior of compartment 56.

Compartment 56 may include one or more electrical connectors 70 (e.g., in the form of one or more bus bars) (FIG. 3) configured to be connected to power take-off cables 72 (FIG. 5) that extend exterior to housing 20 to a system to be supplied with electric power from system 10. In particular, electrical connectors 70 receive electric power from system 10, (e.g., from the interior of housing 20) and serve to transfer at least a portion of the power to power take-off cables 72. Power take-off cables 72, in turn, supply electric power from system 10 to a system being supplied with electric power, such as, for example, a power grid and/or electrically-operated devices/equipment.

Shroud 74 of exemplary system 10 may be configured to protect power load connections 16 from the elements. For example, shroud 74 may provide protection from rain, snow/ice, and/or wind when power take-off cables 72 are connected to electrical connectors 70 to supply electric power for a desired end use. Shroud 74 may serve to provide quick access to compartment 56, while still providing some measure of protection from the elements for power load connections 16. According to some embodiments, when power take-off cables 72 are not connected to electrical connectors 70, shroud 74 may be placed within compartment 56 and access panel 58 may be closed. Latches 68 may be operated to secure access panel 58 in a closed position.

It will be apparent to those skilled in the art that various modifications and variations can be made to the exemplary disclosed flexible shroud and systems and methods for generating electric power. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the exemplary disclosed systems and methods. It is intended that the specification and examples be considered as exemplary only. 

1. A flexible shroud configured to protect a connection between at least one power take-off cable and a power generation system, the shroud comprising: a sheet defining at least one edge, the sheet being flexible and including weather-resistant material; at least one flange operably coupled to the sheet along at least a portion of one edge of the sheet; and at least one securing element associated with another edge of the sheet, wherein the flange is configured to be operably coupled to the power generation system, wherein the sheet is configured to be wrapped at least partially around at least one power take-off cable extending from the power generation system, and wherein the at least one securing element is configured keep the sheet at least partially wrapped around the at least one power take-off cable.
 2. The shroud of claim 1, wherein the sheet is generally rectangular-shaped.
 3. The shroud of claim 1, wherein the at least one securing element includes hook and loop fasteners.
 4. The shroud of claim 1, wherein the at least one securing element includes a drawstring.
 5. The shroud of claim 1, wherein the sheet defines a second edge opposite the one edge, and wherein the at least one securing element is provided along the second edge.
 6. The shroud of claim 1, wherein the sheet includes nylon coated on at least one side with synthetic rubber.
 7. The shroud of claim 1, further including a sealing material on the at least one flange.
 8. A system for generating electric power, the system comprising: an engine configured to output mechanical power; an electric machine configured to convert mechanical power into electric power, the electric machine being operably coupled to the engine; a housing configured to contain at least one of the engine and the electric machine, the housing including at least one wall configured to define an interior and an exterior of the housing; a compartment located at least partially in the interior of the housing, the at least one wall defining an opening for providing access to the compartment from the exterior of the housing; a plurality of electrical connectors operably coupled within the compartment, the electrical connectors being configured to receive electric power generated by the system and provide a connection for power take-off cables; and a flexible shroud operably coupled to the compartment, such that when power take-off cables are coupled to the electrical connectors, the shroud protects at least one of the electrical connectors and/or at least one of the power take-off cables.
 9. The system of claim 8, wherein the electrical connectors include a bus bar.
 10. The system of claim 8, further including an access panel operably coupled to the compartment, wherein the access panel is configured to selectively open and close the opening.
 11. The system of claim 8, wherein the shroud includes a sheet defining at least one edge, and further includes at least one flange operably coupled to the sheet along at least a portion of one edge of the sheet, wherein the flange is operably coupled to the system.
 12. The system of claim 11, further including least one securing element associated with another edge of the sheet.
 13. The system of claim 11, wherein the sheet is configured to be wrapped at least partially around at least one power take-off cable extending from the power generation system.
 14. The system of claim 13, further including at least one securing element configured keep the sheet at least partially wrapped around the at least one power take-off cable.
 15. The system of claim 11, wherein the sheet is flexible and includes weather-resistant material.
 16. A method for connecting at least one power take-off cable to a system for generating electric power, the method comprising: opening an access panel to provide access to a compartment at least partially housing a plurality of electrical connectors operably coupled to the system; lifting a flexible shroud having one edge coupled the system to gain access to at least one of the electrical connectors connecting an end of a power take-off cable to one of the electrical connectors; wrapping a free edge of the shroud around the power take-off cable; and securing the free edge to prevent the shroud from unwrapping from around the power take-off cable.
 17. The method of claim 16, wherein securing the free edge includes using hook and loop fasteners to prevent the shroud from unwrapping from around the power take-off cable.
 18. The method of claim 16, wherein securing the free edge includes pulling a drawstring tight around the power take-off cable. 